use the parts list below to make sure your kit is … · anti-sway bar which is stiffer than the...

of 11 (c) 2018 Total Cost Involved Engineering, Inc. All Rights Reserved.

1937-1939 Chevy Truck Coil-Over Front End

Tech line: 1-855-693-1259 www.totalcostinvolved.com

Read and understand these instructions before starting any work! USE THE PARTS LIST BELOW TO MAKE SURE YOUR KIT IS COMPLETE BEFORE INSTALLATION.

IF ANY PIECES ARE MISSING, PLEASE CONTACT: Total Cost Involved Engineering 855-693-1259

Front Suspension Installation Instructions Thank you for choosing TCI Engineering’s New Coil spring front suspension package. This kit features our completely new upper spring towers that allow traditional shims/washers for alignment adjustments. This design eliminates the T-bolt design that was prone to slipping and throwing your alignment out when you hit pot holes. This new kit also features our new 7/8” anti-sway bar which is stiffer than the ¾” previously offered.

Original Chevy Stock Chassis

New Coil-Spring Front End on Original Stock Chassis

1937-1939 Chevy Truck Coil-Spring Front End Parts List –

Part#: * 230-2354-0CP-C3K-1EX(PLAIN) or 230-2354-0SM-A6K-4GX(SHOW) – The asterisks indicates plain/standard 1 Coil-Spring Cross member 1 Rack & Pinion – Only • * 1937-1939 Chevy Truck Part #: 230-2256-00 • Power Rack Part #: 304-3215-00 2 Upper Control Arms • *Manual Rack Part #: 304-3205-00 • *Part #: 200-2257-00 - Coil Spring Arms Plain 1 Rack & Pinion Bolt Kit • Part #: 200-2257-02 - Coil Spring Arms Polished • Power Part #: 300-3233-00 (PLAIN) • Part #: 200-2257-05 - Coil Spring Arms Black P/C • Power Part #: 300-3233-01 (CHROME) 2 Lower Control Arms • *Manual Part #: 300-3231-00 (PLAIN) • *Part #: 200-2357-00 - Coil Spring Arms (PLAIN) • Manual Part #: 300-3231-00 (CHROME) • Part #: 200-2357-02 - Coil Spring Arms (POLISHED) 2 Short Tie Rod Ends w/hardware • Part #: 200-2357-05 - Coil Spring Arms (BLACK) • *Part #: 301-3236-00 (PLAIN) • Part #: 200-2457-00 - Air Bag Arms (PLAIN) • Part #: 301-3236-01 (CHROME) • Part #: 200-2457-02 - Air Bag Arms (POLISHED) 1 7/8” Anti-Sway bar (bar is located in the rack box) • Part #: 200-2457-05 - Air Bag Arms (BLACK) • *Part #: SWAYBAR-F09-PLN (PLAIN) • Part #: 200-2557-00 - Coil-Over Arms (PLAIN) • Part #: SWAYBAR-F09-CRM (CHROME) • Part #: 200-2557-02 - Coil-Over Arms (POLISHED) 1 Anti-Sway Bar Mount kit • Part #: 200-2557-05 - Coil-Over Arms (BLACK) • *Part #: SWY_BAR_MNT_03-PLN (PLAIN) 2 Spindle Assembly • Part #: SWY_BAR_MNT_03-POL (POLISHED) • Too many rotor and caliper options to list: Anti-Sway Bar Heim kit 2 Shocks • *Part #: SWY_BAR_HIEMS38MOD • *Part #: SKBDY09-5 (PAINTED SHOCKS) Anti-Sway Bar Bolt kit

http://www.totalcostinvolved.com/


• Part #: SKBDY03-0 (BILLET COIL-OVERS) • *Part #: SWY_BAR_BOLT_01-PLN (PLAIN) • Part #: SKBDY03-3 (POLISHED BILLET COIL-OVERS) • Part #: SWY_BAR_BOLT_01-CRM (CHROME) Springs • • *Part #: SPRINGM300B (REGULAR COIL SPRING) • • Part #: SPRINGB600B (BEEHIVE SPRING FOR COILOVER) •

~ New Coil-Spring Front End ~


Installing the boxing plates: Measure the width of the top and bottom of the rails. Cut or grind the longer lip back to make them both the same width. This will allow installation of the boxing plate square to the frame. *NOTE* This picture is with the frame upside down. The boxing plate is tapered. Place the plate onto the frame within the corresponding taper/size.

It is important that the boxing plates be positioned on the edge of the frame rail so that you can maximize weld penetration. This will insure there is enough weld to grind and smooth out the corners. Use a square to make sure that the plates are square to the frame. Tack weld all 4 corners of the plate to the rail and make sure they are still square. Once the boxing plates are confirmed square you can begin welding them in place. Weld 6” sections at a time switching from driver to passenger so heat is kept to a minimum.

Locating the axle center line: Measure 17¼” from the original leaf spring mounting hole to locate the new cross member. Using the illustration to the left, find and mark the axle center line on both the passenger and driver side frame rail.

Installing the Cross member: 2 degrees frame rake(vehicle stance) is typical. The flat area on top of the cross member should be level to the ground or 0 degrees when the frame is at proper rake. *NOTE* The frame pictured is sitting at 0 so the cross member is being installed @ 2 degrees. Center the cross member on the axle center line mark made earlier. Only tack weld the cross member into place at this time. *NOTE* Grinding the cross member to make it fit between the rails may be necessary.


Installing the C-notches: Once the wheelbase is marked on the frame you can now properly install the c-notches. Using the diagram on the left measure 5.125” forward of the wheel centerline. This will be the center of the c-notch. Now measure up the rail 1.5” and mark it. Use the c-notch as a template on the frame using the mark on the frame as the center/top of the c-notch. Cut the frame to match the c-notch. *NOTE* Make sure not to cut too much of the frame. Place c-notches into the frame and weld in place.

Modifying the factory radiator cross member: In order for the rack & pinion to fit into the chassis you will have to remove part of the radiator cross member. You can use the rack & pinion as a template. Skip forward to page 10 of the manual for the rack installation instructions. Trim the crossmember back so the rack & pinion has at least ½” clearance.

Installing the lower control arms: *NOTE* The acorn side of the 5/8” shaft faces forward. The arrows in the picture denote where the washers are used. There is no washer placed against the front side of the cross member. There are only 3 washers used per side of the vehicle. Install the 5/8” full nylock nut on the back side of the shaft and torque to 75 ft. Ibs. *NOTE* Driver side control arm is pictured


Installing the spring towers: The tall part of the control arm mount goes towards the front of the truck. This is the built-in anti-dive. Follow the measurements in the illustration above for exact placement of the towers side to side & front to back. It will be critical that the towers are installed square and parallel to each other at 27” +/- 1/16” apart outside to outside of arm mount faces. Also, the arm mount face must be vertical +/- .5 degrees. This will insure proper alignment. It may be necessary to grind some material off the towers where they come up against the side of the frame to achieve the proper measurement.

As a reference, install the shock onto the lower control arm and pull the shock shaft through the upper spring tower hole. The shock shaft should line up directly with the hole in the cone when everything is correct.


Once proper placement is confirmed a couple tack welds can be placed at the top and the side of the tower/frame. Double check all measurements. Now you can weld the spring towers and cross member into place.

**Addendum** Ridetech Coil-Over upgrade Turn the adjustment ring on the shock as far down as possible. Install the spring onto the shock with the small tapered side of the spring down against the flat rubber insulator and adjuster ring.

Place the shock onto the lower control arm and install the provided ½” button head bolt.

Install the nylock on the opposite side and tighten down


Use a T10 Torx head to remove the screw at the top of the shock/adjuster knob.

Remove the adjuster knob and screw and set it aside for now.

Remove the nylock, thick washer and concave insulator and set them aside for now. *NOTE* There are two halves of the concave insulator, leave the bottom half installed on the shock.


You can now lift the lower control arm and shock/spring combo up into the upper hat assembly. Align the shock shaft into the center hole of the upper hat. This is where making sure the adjuster ring was all the way down or not will make all the difference. If it wasn’t the stud will not protrude far enough to reinstall the top end of the shock. *NOTE* Make sure the shock shaft is fully extended

Reinstall the concave insulator and thick washer on top of the upper hat assembly

Reinstall the nylock and tighten it down


Using the same T10 Torx you ca now reinstall the adjuster knob and screw

Installing the upper control arms: Use three of the provided .090” thick washers between the tower and the control arm shaft on each bolt. The rest can be placed under the head of each bolt and under the lock nut. These spacers may need to be moved around when final alignment is performed. Once all the hardware is in place go ahead and set the bolts in the center of alignment slots and tighten down. The slotted arm mount holes will make it easy to add in extra positive caster for power rack applications.

Installing the spindle assemblies: Place the spindle onto the lower ball joint with the steering arm facing forward with the large I/D tie rod end taper facing down.(The tie rod end goes up into the spindle) Place the ball joint washer first and then the castle nut. Torque the lower ball joint to 90 ft. lbs and install the cotter pin. The lower ball joint is a MOOG K719

Pull the upper control arm down onto the spindle. Place the ball joint washer first and then the castle nut. Torque the upper ball joint to 70 ft. lbs and install the cotter pin. The upper ball joint is a MOOG K772 *NOTE* Caliper Fittings: GM Calipers = 10mm x 1.5 Wilwood Calipers = 1/8” NPT


Centering the rack assembly: The rack needs to be centered to allow equal steering left to right. On a bench, turn the pinion out to lock one way. Measure from a convenient point to the end of the inner tie rod. (This rack was 17 ¾). Turn the pinion of the opposite lock position and measure from the same point to the end of the same tie rod (11 ¾). 17 ¾ minus 11 ¾ = 6. Divided by 2 = 3 Add that number to the smallest measurement (11 ¾” + 3” = 14 ¾”) and turn the pinion back till you get that measurement and your rack is centered.

Installing the rack and pinion: Place the rack on the cross member brackets as shown. Use the supplied 5/8” hardware to fasten it into place. The picture shows a power rack that requires a 5/8” spacer between the rack and the mounting brackets. A manual rack bolts directly to the mounting brackets not needing these spacers. Torque bolts to 90 ft. lbs *NOTE* Power Rack & Pinion fittings: 9/16”-18 Pressure side & 5/8”-18 Return side

Install the jam nut and outer tie rod end onto both sides of the rack. With the rotors pointing straight ahead(0 toe) install the tie rod ends into the bottom of the steering arm. Torque the tie rod end to 60 ft. lbs. and install the cotter pin. *NOTE* Rack & Pinion output shaft: Manual rack = 9/16”-26 spline Power rack = ¾”-36 Spline

Installing the anti-sway bar: Slide the lock ring collar over the bar on each side first. The split bushings go over the bar and then the aluminum blocks slide on over the bushings.


No returns or exchanges without a RMA#. Packages must be inspected upon receipt & be reported within 10 days.

If you are missing parts from your kit, TCI Engineering will send the missing parts via FedEx or U.S. mail ground.

Returned packages are subject to inspection before replacement/refund is given.(Some items will be subject to a 15% restocking fee)

Thank you for your business!

The anti-sway bar mounts to the rear of the cross member below the lower control arm pins. Use the supplied hardware to install the aluminum blocks onto the cross member. Torque to 35 ft lbs. Center the anti-sway bar and lock down the set screws against the bushings.

The sway bar routes from behind the cross member under the control arms and hooks up to the front of the control arms. Use the supplied hardware to install the heim joints with the male on the bottom. *NOTE* You can adjust the preload(or lack thereof) once the vehicle is ready to be driven. Disconnect one heim, place driver in the driver’s seat, adjust the loose heim until it goes onto the anti-sway bar with zero load.

Alignment specifications Caster: Power rack 4-6 degrees positive Manual rack 2-4 degrees positive Camber: 0 Degree Toe-in: 1/32 to 1/16 inch Adjust the Coil-overs until the lower control arms are level to the ground. You can now perform the final alignment. AXLE STUD SIZES: 4.5” Bolt circle rotors = ½”x20(’75-’80 Ford Granada) 4.75” Bolt circle 10.5” rotors = 12mmx1.5(’82-’87 Camaro) 4.75” Bolt circle 11” rotors = 7/16”x20(’75-’80 Granada redrilled) ALL Wilwood hubs = 1/2”x20

use the parts list below to make sure your kit is … · anti-sway bar which is stiffer than the...

Documents